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Lecture No-16
Electro-Chemical Grinding
The commutator is an electrolytic spindle having carbon brushes and holds the
grinding wheel. It receives a negative charge from the DC power supply and the
workpiece is given a positive charge. In ECG process, the grinding wheel slightly
touches the workpiece. Electrolyte is supplied on-to the grinding wheel near the
workpiece such that the wheel carries it through the cutting process thereby
resulting in an electro-chemical action. A nozzle similar to the one which carries
coolant in a conventional grinding process is provided, which enables the flow of
the electrolytic fluid to the work-tool cont act area. Th e electrolyte along wi th wheel
wo rks simulta neously in t he process o f cutting. T he electro-c hemical cells thus
formed further oxidize the surface of th e workpiece. The wheel carries awa y the
formed oxides the reby exposing the fresh metal layers beneath the workpiece.
In this pr ocess of E CG, the maj or material removal activity takes place by th e
electrolytic action (around 90%). Rest of the metal removal takes pl ace due to th
e grinding action alo g with abrasives used (embedd ed in the wheel). This
mechanical action contributes to around 1 0% due to abrasive action of th e
conductin g grinding wheel. The pressure ap plied on the grinding wheel is als o
much les er than the conventional grinding process. Thus the very basic necessi ty
of frequent wheel dr essings and truing as in the case of conventio nal process is
also elimi nated.
The sche matic of the electrochem ical grinding process is shown in Fi g. 3.16.1
Process Characteristics
The life of grinding wheel in ECG process is very high as around 90% of the
metal is removed by electrolysis action and only 10% is due to the abrasive
action of the grinding wheel.
The ECG process is capable of producing very smooth and burr free edges
unlike those formed during the conventional grinding process (mechanical).
The heat produced in the ECG process is much less, leading to lesser distortion
of the workpiece.
The major material removal activity in ECG process occurs by the dissolving
action through the chemical process. There is very little tool and workpiece
contact and this is ideally suited for grinding of the following categories:
Fragile work-pieces which otherwise are very difficult to grind by the
conventional process
The parts that cannot withstand thermal damages and
The parts designed for stress and burr free applications.
Applications